Chevrolet - Sonic - Parts Catalogue - 2018 - 2018

Chevy Sonic 1.4L Intake Manifold Install Time: 3 hours In the Box: • • • • • • • • • (1) Racer X Intake manifold (6) M8x1.25 bolts (4) M6x1 bolts (2) 1/8” NPT plugs (1) 3/8” NPT plug (1) 1/4” NPT 90 degree barb (4) Small O-rings (1) Large O-ring (1) PCV O-ring Tools: • • • • • • • • • Socket driver 10mm socket 13mm socket Pliers Crescent wrench Razor blade NPT thread sealer Flat head screwdriver Allen keys Instructions: 1. Start by removing the OEM air intake assembly and intake manifold. We suggest following the service manual, although there are several online sites with removal instructions. We recommend removing the fuel rail from the vehicle. This means relieving fuel pressure from the rail. Please do so in a safe manner and again follow the service manual for this procedure. 2. Optional PCV kit shown. Use pipe thread sealer on all fittings. Only 2 clamps are supplied with the kit. They should be used where indicated. Be sure to check valve flow is in the correct orientation during installation. (Figure 1) 3. The fuel rail mounting brackets must be bent to accommodate the mounts on the intake manifold. We suggest using a set of pliers and a crescent wrench. Slowly bend the tabs down toward the injectors. Check the rail fitment, the tabs should be parallel to the mounting points on the manifold. (Figure 2) 4. Once the fuel rail is ready to be installed onto the manifold begin by lubricating the injector o-rings. Once properly lubricated, angle the rail at the bottom toward the injector ports. (Figure 3) 5. Slowly insert the injectors into the manifold, firmly press from the top of the fuel. The plastic guides below the o-rings may bind slightly, this is normal. Take your time and be sure not to tear an o-ring. A fully seated injector should look like this. (Figure 4) © 2018 Racer X Fabrication 6. Finally insert the small nylon spacers between the rail mounts and the manifold mount. Then thread in the M6x1 bolts to the bottom of the manifold and finger tighten. Once both are installed, use a 10mm socket to tighten bolts. (Figure 5) 7. Install manifold to cylinder head. It helps to remove the evap hose and canister for additional clearance and room to work. Before bolting the manifold to the cylinder head, install the injector electrical connectors. Then using the supplied (6) M8x1.25 bolts, mount the manifold to the cylinder head. Remember to ground the rail to one of the bolts. Once in place, tighten bolts to 15ft/lbs. 8. Next install the OEM throttle body using the supplied M6x1 40mm bolts. Start all bolts before tightening, use a 10mm socket and tighten throttle body. Install IC tube and tighten clamp. (Figure 6) 9. Install vacuum fittings, plugs and MAF sensor. We recommend using a thread sealing paste over tape. The thread sizes on the manifold are as follows: (2) 1/8 NPT, (1) 1/4” NPT, (1) 3/8” NPT, (1) M6x1 for MAF sensor. (Figure 7) 10. The OEM thermoset line must be cut from the brake booster on the master cylinder. Using a razor blade, carefully score the line so it can be separated from the fitting. Once removed, run the supplied 3/8” ID line from the fitting to the supplied 90 degree 1/4” NPT barbed fitting. (Figure 8) 11. The brake booster line can be seen here. (Figure 9) 12. Using the supplied 1/4” ID hose, run from the turbo BPV to the solenoid and manifold using the supplied 3/16” vacuum tee. The small 5/32” hose should be used to connect to the solenoid. The red silicone caps should be placed according to the picture. Be sure to use zip ties or clamps on the 1/4” line at the tee connection. (Figure 10-11) 13. The line routing can be seen in these additional pictures. (Figure 12-13) 14. Run the 1/2” ID hose from the PCV tee to the turbo vacuum source. The OEM PCV line will have to be cut from the OEM turbo fitting. Again, using a razor blade, score the thermoset line and remove. Using the supplied 5/8” hose connect the OEM fitting using the 1/2” to 5/8” hose splice connect the two hoses. (Figure 14-15) 15. Finally, install EVAP canister and line to manifold. The OEM fitting snaps into the top of the manifold. The small plastic wiring harness located at the center of the manifold will need to be removed to allow for more movement. Install all OEM electrical connectors, fuel system components and air intake assembly. Key on vehicle and check for fuel leaks, if there are no leaks start vehicle. Again double check for leaks. Installation complete. (Figure 16) © 2018 Racer X Fabrication © 2018 Racer X Fabrication © 2018 Racer X Fabrication © 2018 Racer X Fabrication Questions, comments, or concerns? Email [email protected]. © 2018 Racer X Fabrication